Make-your-own smoking article with controlled burn rate

ABSTRACT

The burn rate of a “make-your-own” cigarette is controlled by applying an add-on material such as a refined form of fibrous cellulose to the paper sleeve and/or tobacco rod wrapper that are used to form the assembled cigarette.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119 to Provisional Application No. 60/592,190 filed on Jul. 30, 2004, the entire content of which is hereby incorporated by reference.

BACKGROUND

Preferred embodiments relate to make-your-own cigarettes and packaged kits and components of make-your-own cigarettes, including kits whose components are unsmokable in their unassembled retail (kit) form.

Examples of consumer-rolled cigarettes and systems for making your own cigarette are disclosed in U.S. Pat. Nos. 6,443,161; 6,206,008; 6,223,895; 5,197,495; 5,133,366 and 4,534,367; and in U.S. patent application Ser. No. 2002/0166561. In EP 155,514 and EP 178,605, a tobacco rod is only smokable when it is inserted into a cigarette paper sleeve or “tube”.

In the alternative, a make your own cigarette may comprise a kit of a paper tube and a quantity of shredded tobacco, with which the smoker places the loose tobacco shreds into the paper tube, usually with the assistance of a plunger tool or the like.

It would be desirable to provide a make-your-own cigarette, a kit for a make-your-own cigarette and components for same having a controlled burn rate when assembled, so as to reduce ignition propensity potential of the make-your-own cigarette.

SUMMARY

According to a first embodiment, a smoking article kit comprises a rod of smokeable material having a rod wrapper and a paper tube, wherein the paper tube and/or the rod wrapper comprise a base web and an applied pattern of add-on material which alters the burn rate of the assembled smoking article.

According to a further embodiment, a component of a make-your-own smoking article comprises a paper base web with one or more regions of an applied pattern of add-on material which alters the burn rate of the assembled smoking article.

The add-on material can be refined fibrous cellulose material in the form of a dried banded region or a plurality of dried banded regions. Preferably, the banded region has a basis weight of from about 25 to 40 g/m². The refined fibrous cellulose material can optionally comprise a binder, and the add-on material can comprise a coating in a repeating pattern.

The bands can have a width of from about 1 mm to 10 mm and can be spaced about 5 mm to 40 mm apart. In a further embodiment, the paper tube can comprise a band having a width of from about 1 to 10 mm. According to a preferred embodiment, the bands are uniformly spaced. Preferably, the dry weight of the refined, fibrous cellulose add-on material on the paper base web is preferably between approximately 0.5 to 15 g/m², more preferably approximately 1 to 12 g/m².

The component of a make-your-own smoking article can comprise a paper sleeve (e.g. a paper wrapper of a tobacco rod) for receiving cut tobacco filler or a tobacco rod of the assembled smoking article and the pattern can be on the interior or on the exterior of the sleeve.

The paper tube (or sleeve) can further comprise a tobacco filter element and/or the rod of smokeable material can comprise a traditional cigarette. The filter element is preferably attached at one end portion of the paper sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a kit in accordance with a preferred embodiment in an unassembled condition.

FIG. 2 is a perspective view of a kit in accordance with a second preferred embodiment in an unassembled condition.

FIG. 3 is a perspective view of a kit in accordance with a third preferred embodiment in an unassembled condition.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A make-your-own smoking article comprises a paper sleeve and a tobacco rod having a wrapper, wherein the paper sleeve and/or wrapper comprise a paper base web with an applied pattern of add-on material such as a refined form of fibrous cellulose material.

A component of a make-your-own smoking article comprises an empty tubular base web with one or more regions (e.g., banded regions) of an applied pattern of add-on material such as a refined form of fibrous cellulose material. Optionally, the component may further comprise a filter element attached at one end portion of the empty tubular base web, preferably attached with a tipping paper. The aforementioned pattern can be applied to the interior and/or the exterior of the tubular base web and can extend circumferentially about and/or longitudinally along the tubular base web. The add-on material preferably comprises one or more circumferential banded regions.

Preferably, the burn rate of the make-your-own cigarette is sufficiently reduced at the banded regions that the cigarette extinguishes when placed on a substrate.

Referring to FIG. 1, a kit 50 of a make-your-own cigarette comprises a paper tube (sleeve) 10 and a tobacco rod 2, the latter being dimensioned so as to be slidingly insertable into the paper tube 10 so as to establish a complete assembled cigarette. The tobacco rod 2 preferably comprises a rod wrapper 4 and a column of tobacco filler within the rod wrapper 4. The column of tobacco may comprise shreds of a single variety of tobacco or a blend of tobaccos, together with or without other components such as reconstituted tobaccos, expanded tobaccos, flavors and the like.

Preferably, the paper tube 10 comprises a hollow (unfilled) tubular wrapper 11 and a filter plug (or plugs) 5 that is/are attached to the tubular wrapper 11 with a tipping paper 14. In the alternative, the filter plugs 5 may be disposed within an end portion of the paper tube 10. The tubular wrapper 11 includes circumferential banded regions 12 of additional add-on material for purposes of controlling (lowering) burn rate at the banded regions 12. Preferably, the tubular wrapper 11 is formed from a ribbon of paper web that is rolled into a tubular form with overlapping edge portions that are glued together with an adhesive along a seam line 15. The “base web” portion of the tubular wrapper 11 is defined as the portion of the paper without the banded regions of increased basis weight.

The add-on material can be a refined form of fibrous cellulose or other material effective in reducing the burn rate of the cigarette across regions of the add-on material. Preferably, the add-on material is applied to the paper sleeve and/or wrapper in the form of bands to form banded paper that can reduce the static burn rate of the paper tube. Thus, the burn characteristics of a make-your-own cigarette is controlled.

The add-on material may comprise a solution such as an aqueous solution of alginate, pectin, carboxymethyl-cellulose and/or polyvinyl alcohol. Further, the add-on material may comprise a fibrous slurry such as an aqueous slurry of microcrystalline cellulose, cellulon bacterial cellulose and/or highly refined wood pulp fibers. The add-on material may comprise a natural polymer soluble in non-aqueous solvents.

The tobacco rod 2 is preferably not smokeable by itself. Optionally, the rod wrapper 4 may comprise a high permeability web.

Optionally, the paper tube 10 may be constructed essentially of a tubular wrapper 11 without the filter plugs 5, with or without inclusion of a tipping paper 14.

Optionally, the banded regions 12 may extend longitudinally along the tubular wrapper 11, or in a pattern, instead of or in addition to being oriented circumferentially.

Optionally, the add-on material of the banded regions 12 may comprise a binder, a filler (chalk), a burn modifier, a starch or other polysaccharride and/or a flavorant, in lieu of or in addition to fibrous cellulose.

The term “fibrous cellulose” is used herein to describe cellulose in the form of either fibers, fibrils or microfibrils, or any combination thereof in various states of subdivision. “Fibrils” are the threadlike elements of the wall of the cellulose fiber visible with an optical microscope. Upon examination by electron microscopy “microfibrils” are found to consist of still finer “fibrils.”

Still referring to FIG. 1, the base web of the tubular wrapper 11 preferably comprises a cigarette paper of conventional specifications onto which has been applied a slurry of highly refined fibrous cellulose (e.g., fibers, fibrils, microfibrils, or combinations thereof) or other add-on material. The fibrous cellulose or other add-on material can be applied using various spray, coating or printing techniques, including application techniques that utilize a moving orifice applicator at the forming section of a paper-making machine as described in commonly owned U.S. Pat. Nos. 5,997,691 and 6,596,125, which patents are hereby incorporated by reference in their entirety. Alternatively, the highly refined cellulose or other aforementioned forms of add-on material may be applied on-line or off-line of the base paper making apparatus beyond the wet end of the paper making machine. Thus, paper having add-on material for forming components of make-your-own smoking articles can be mass produced.

The base web of the tubular wrapper 11 may have a basis weight of approximately 25 to 40 grams per meter squared (gsm), more preferably, approximately 25 to 26 gsm; a permeability of approximately 15 to 90 CORESTA units, more preferably 20 to 60 CORESTA, a filler (chalk) loading of 20 to 40 dry weight percent, more preferably approximately 25 to 35 percent; and a citrate (burn additive) loading of approximately 0 to 2 dry weight percent, preferably approximately 0.6%. However, the banded regions, although they possess increased basis weight, are preferably of substantially the same thickness as the base web. The add-on material, when comprising a highly refined fibrous cellulose (and optionally a chalk loading of 1 to 12%), may have, when taken alone, a basis weight of approximately 0.5 to 15 gsm, more preferably approximately 1 to 12 gsm.

The base web of the tubular wrapper 11 may include other suitable conventional fillers, or a combination of fillers, may be used such as the various phases of calcium or magnesium carbonates, or the like, along with hydroxides of magnesium or the like. Other additives such as citrates, phosphates, succinates or the like may also be used in the paper sleeves. Examples of permeable paper wrappers for use in smoking articles are disclosed in U.S. Pat. No. 5,921,249.

Cigarette papers in use cover a wide range in porosity and burn rate. The inherent porosity of the paper varies from about 2 to about 150 CORESTA units. Papers with lower values for inherent porosity require less added fibrous cellulose or other add-on material in the banded region to control the burn rate than papers with higher values. Therefore the level of slurry or other add-on material applied to the base paper can be adjusted based on the type of base paper used and the desired burn characteristics. According to a preferred embodiment, the base paper has a basis weight of about 25 to about 40 g/m²; the inherent porosity is in the range from about 20 to about 60 Coresta units; the calcium carbonate concentration is in the range from about 25 to about 35 percent; and the citrate concentration is in the range from about 0 to about 2 percent.

Banded regions can be formed on the paper wrapper or high permeability paper by any suitable technique including those disclosed in commonly-owned U.S. Pat. Nos. 5,997,691; 5,474,095; 5,417,228; 5,263,999 and 5,191,906, the disclosures of which are hereby incorporated by reference. Banded cigarette paper is disclosed in U.S. Pat. Nos. 4,739,775 and 4,615,345. A slurry of the fibrous cellulose or other add-on material can be applied to the paper wrapper and/or high permeability paper in the desired locations and patterns, during or after the initial manufacturing of the base paper wrapper. If the slurry is applied during the initial manufacturing, this step should preferably be performed beyond the wet end of the base paper making apparatus.

The dimensions of the banded regions will affect the bum characteristics of the paper and, consequently, the assembled cigarette. The bands 12 may be established at any desired interval and width depending on the particular desired burn control rate. Preferably, bands are applied at intervals of about 5 mm to about 40 mm, more preferably about 15 mm to 30 mm apart. The width of the band may be varied depending on the type of cigarette and paper used in addition to the type and level of slurry or other add-on material applied. Preferably the width of a band is about 1 mm to 10 mm, more preferably 4 mm to 8 mm.

Referring now to FIG. 2, a second alternate embodiment provides a kit 50′ that comprises an empty paper tube 10 substantially the same as described in the first preferred embodiment, but with an absence of banded regions thereon. Instead, banded regions 12′ are provided at locations along the tobacco wrapper 4 of the tobacco rod 2. As with the first embodiment, the banded regions 12′ may be applied either on the inside or the outside of the tobacco wrapper 4.

Referring now to FIG. 3, a third embodiment provides a kit 50″ comprising hollow (empty) paper tubes 22, 22′ that slide over the outside of the tobacco rod portion 24 of a conventional (lit end) cigarette 28 (filtered or unfiltered). Each paper tube 22 slidingly fits over the tobacco rod portion 24 and includes banded regions 12″ (as previously described), so that when the cigarette 28 is smoked with the paper 22 in place, the cigarette 28 exhibits static burn rate attributes at the banded regions 12″ so as to reduce its ignition propensity levels when smoldering on a substrate.

The kit 50″ may include paper tubes 22 having essentially the same band width or spacing for the banded regions 12′ or instead may include a collection of different tubes 22, 22′ that feature bands of different dimensions, placement and/or make-up, so as to meet a variety of differing needs such as customer preferences and differences in statutory or regulatory requirements. Alternatively, the paper tubes 22 might be reduced in length to that of the banded regions 12″ so as to resemble rings.

The foregoing has described the principles, preferred embodiments and modes of operation of make-your-own smoking articles. However, the foregoing should not be construed as being limited to the particular embodiments discussed. For example, the tobacco rod 2 of the first embodiment may be replaced by a collection of loose shredded tobacco that is inserted into the paper tube 10, preferably with the assistance of a plunger apparatus. Further, the discussion herein related to the refined form of fibrous cellulose or other add-on material is provided for means of explanation and as illustration of preferred embodiments. Thus, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope as defined by the following claims.

All of the above-mentioned references are herein incorporated by reference in their entirety to the same extent as if each individual reference was specifically and individually indicated to be incorporated herein by reference in its entirety.

While the invention has been described with reference to preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and scope of the invention as defined by the claims appended hereto. 

1. A smoking article kit comprising: a rod of smokable material having a rod wrapper; and a paper tube; said paper tube and/or rod wrapper comprising base web and an applied pattern of add-on material which alters the burn rate of the assembled smoking article.
 2. The smoking article kit of claim 1, wherein add-on material is refined fibrous cellulose material in the form of a dried banded region.
 3. The smoking article kit of claim 2, wherein the refined fibrous cellulose material comprises a plurality of dried banded regions.
 4. The smoking article kit of claim 3, wherein the bands have a width of about 1 mm to 10 mm.
 5. The smoking article kit of claim 3, wherein the bands are spaced about 5 mm to 40 mm apart.
 6. The smoking article kit of claim 3, wherein the bands are uniformly spaced.
 7. The smoking article kit of claim 2, wherein the banded region has a basis weight of from about 25 to 40 g/m².
 8. The smoking article kit of claim 1, wherein the add-on material comprises a coating in a repeating pattern.
 9. The smoking article kit of claim 2, wherein the refined fibrous cellulose material comprises a binder.
 10. The smoking article kit of claim 1, wherein the paper tube further comprises a tobacco filter element and/or the rod of smokeable material comprises a traditional cigarette.
 11. The smoking article kit of claim 2, wherein the dry weight of the refined fibrous cellulose on the paper base web is between about 0.5 to 15 g/m².
 12. The smoking article kit of claim 1, wherein the paper tube comprises a band having a width of from about 1 to 10 mm.
 13. The smoking article kit of claim 1, wherein the pattern of add-on material reduces the burn rate of the assembled smoking article
 14. The smoking article kit of claim 1, wherein the add-on material comprises alginate, pectin, carboxymethyl-cellulose, polyvinyl alcohol, microcrystalline cellulose, cellulon bacterial cellulose, highly refined wood pulp fibers and/or a natural polymer.
 15. A component of a make-your-own smoking article comprising a paper base web with one or more regions of an applied pattern of add-on material which alters the burn rate of the assembled smoking article.
 16. The component of claim 15, wherein the component comprises a paper sleeve for receiving cut tobacco filler or a tobacco rod of the assembled smoking article.
 17. The component of claim 16, wherein the pattern is on the interior of the sleeve.
 18. The component of claim 16, wherein the pattern is on the exterior of the sleeve.
 19. The component of claim 15, wherein the component comprises a paper wrapper of a tobacco rod.
 20. The component of claim 15, wherein the add-on material is refined fibrous cellulose material.
 21. The component of claim 20, wherein the refined fibrous cellulose material comprises a plurality of dried bands.
 22. The component of claim 21, wherein the bands have a width of about 1 mm to 10 mm.
 23. The component of claim 21, wherein the bands are spaced about 5 mm to 40 mm apart.
 24. The component of claim 21, wherein the bands are uniformly spaced.
 25. The component of claim 15, wherein the add-on material comprises refined fibrous cellulose material having a basis weight of from about 25 to 40 g/m².
 26. The component of claim 15, wherein the add-on material is a coating.
 27. The component of claim 15, wherein the add-on material comprises refined fibrous cellulose material and a binder.
 28. The component of claim 15, wherein the add-on material comprises refined fibrous cellulose having a dry weight on the paper base web of between about 0.5 to 15 g/m².
 29. The component of claim 15, wherein the add-on material comprises alginate, pectin, carboxymethyl-cellulose, polyvinyl alcohol, microcrystalline cellulose, cellulon bacterial cellulose, highly refined wood pulp fibers and/or a natural polymer.
 30. The component of claim 16, wherein the component further comprises a filter element attached at one end portion of the paper sleeve.
 31. The component of claim 16, wherein the paper sleeve is a band. 